Apparatus for catalytic conversion reactions



Jan. 4, 1944.

P. MATHER APPARATUS FOR CATALYTIC CONVERSION REACTIONS Original Filed Feb. 26. 1940 3 Sheets-Sheet 1 II I I N \{ENTOR PERCY MATHER ATTORNEY 9 I MATHER I 2,338,346

APPARATUS FOR CATALYTIC CONVERSION REACTIONS- Originai Filed Feb. 25. 1940 3 Shets-Sheat 2 INVENTOR F'IG.. 3 PER Y MATHER TTQRNEY Patented Jan. 4, 1944 srrsm'rus ron cs'rsrr'rro CONVERSION amcrrous Percy Mather, Chicago, 111., assignor to Universal Oil Products Company, Chicago, 11]., a corporation of Delaware Original application February 26, 1940', Serial No.

320,815. Divided and this application September 30, 1940, Serial No. 359,084

6 Claims. 01. za-zss) This is a division of my co-pending application Serial Number 320,815, filed February 26, 1940, which has become Patent No. 2,319,620.

This invention relates to an improved form of reactor for conducting catalytically promoted conversion reactions and particularly those of the type devoted to the conversion of hydrocarbons, such as catalytic cracking, dehydrogenation, isomerization, cyclization, reforming, etc., wherein heavy carbonaceous conversion products are deposited on the catalyst and must be periodically. removed therefrom to restore its activity.

In such reactions conversion of the hydrocarbons is usually endothermic, in varying degrees, and reactivation of the catalyst, which is exothermic, is accomplished by burning the deposited-carbonaceous materials therefrom in a stream of oxygen-containing gas.

The range of temperature conditions. which may be employed with best results for any specifice catalyst and charging stock is relatively narrow and, during reactivation of the catalyst,

' care must be exercised to prevent. the developmnt of temperatures which cause destruction or permanent impairment to the activity of the catalyst. For these reasons, it has heretofore been common practice to control temperatures during both processing of the hydrocarbon reactants and reactivation of the catalyst by circulating 4 a convective medium in indirect heat transfer relation wiith the catalyst, reactants and reactivating gases. With the relatively short alternate periods of processing and reactivation in each reactor, which are ordinarily required for good results, this method of temperature control is one of the major items of expense both in the initial installation and in operation.

The improved form of apparatus provided by the invention permits a different mode of operation in which the aforementioned conventional method of temperature control and its'attendant expense is obviated in a simple and advantageous manner.

To accomplish the improved method of operation, the catalytic material employed'to promote the conversion reaction is divided into a plurality of relatively shallow beds in each reactor of the system and provision is made for dividing the stream of hydrocarbon reactants, which is supplied to the reactor in heated state, into a plurality of substantially equal smaller streams, each of which is passed through only one of the several catalyst beds, resulting fluid conversion products being'thence removed from the reactor. During reactivation of the catalyst a stream of oxygen-containing reactivating gases, which is supplied to the reactor in heated state, is likewise divided into a plurality of substantially equal smaller streams, each of which is passed through only one of the several catalyst beds, the resulting spent orpartially spent reactivating gases and combustion products being thence removed from the reactor.

With this method of operation desirable conditions, approaching those obtainable in a conventional operation in which a convective medium is employed to heat the catalyst bed and reactants during processing and cool the catalyst bed and reactivating gases during reactivation, are obtained without the use of such external temperature control.

.As compared with an operation in which other conditions (such as the total volume of catalyst employed, the temperature and rate at which the heated reactants are supplied to the reactor and the type of catalyst and charging stock employed) are the same but wherein the total reacants' and reactivating gases arepassed through the entire mass of catalyst and no external heating or cooling means are employed, the improved method of operation made possible by the present invention results in more uniform temperatures throughout the catalyst mass during processing and reactivation, a higher minimum and higher average temperature in the catalyst mass during processing, a lower maximum and lower average temperature in the catalyst mass during reactivation, as well as lower mass velocities and hence lower pressure drop through the reactor. Due to more uniform temperatures throughout the catalyst mass during processing, the deleterious heavy conversion products deposited on the catalyst mass are more uniformly distributed throughout the latter and the rate of decreasing catalyst activity is much lower. The more uniform deposition of deleterious carbonaceous material is also advantageous during reactivation since it materially assists in-preventing the development of excessive temperatures at any point in the catalyst mass.

Depending upon the type of catalyst and charging stock employed, the ratio of catalyst volume to reactants processed in a given time optimum quality and yield of gasoline produced,

be somewhat less or somewhat more than the length of processing time required to decrease the activity of 'the catalyst to a pointwhere its reactivation is necessitated, and the length of each processing period will correspond to which ever of the aforementioned times is the shorter. By properly controlling the relative proportions of oxygen and inert ingredients in the reactivat ing gas stream and properly regulating the rate at which the reactivating gases are supplied to the reactor, the length of the reactivating period may be controlled to approximately correspond to the length of the processing periods.

In the accompanying diagrammatic drawings Fig. 1 is an elevation shown partially in section, of a specific form of reactor embodying the features of the invention.

Fig. 2 is an enlarged cross-sectional detail of one of the catalyst trays 8 of Fig. 1.

Fig. 3 is an elevation, shown partially in section, of the upper and lower portions of a modied form of reactor embodying the features of the invention.

Fig. 4 is a diagram of a process flow wherein two reactors of the improved type provided by the invention are arranged for alternate processing of the hydrocarbonsto be converted and reactivation of the catalyst in each reactor.

Referring to Figs. 1 and 2, an elongated cylindrical shell of the reactor indicated by the reference numeral I, is provided with a lower head 2 and a removable upper head 4 which is flanged and bolted, as indicated at 5, to shell I. Inlet nozzle 6 is providedin the removable upper head 4 and outlet nozzle I is provided in the lower head 2. 4

A plurality of catalyst trays 8 are provided within shell I between its upper and lower heads and, as illustrated in Fig. 2, each of these members comprises a relatively flat deck 9 having upturned edge portions I at its outer circumference and a central tubular member II extending from above the level of the upturned edges III to beneath the level of deck 9. 4

A pervious imember I2 diagrammatically shown in Fig. 2 as a screen, although a perforate plate or the like may be substituted, is provided between the top of the upturned edges I8 and deck 9 and extends from the upturned 'edges III to the central tubular member II. Screen I2 .is attached,

in the particular case here illustrated, to the up-' turned edges III of the tray by'turning the outer edge of the screen downward and holding it between the tray and a ring-shaped member I3 which is welded or otherwise secured to the tray. A similar attachment comprising ring-shaped member I4 anchors the inner edge of the screen to member I I.

upwardly into the reactor and having an upper.-

end similar to the upper ends of members II of the trays I8, so that the lower ends of member II of the lowermost tray nest within the upper end of member 20.

Each of the trays 8 is sufficiently smaller than the internal diameter of shell I that a space 2| is provided therebetween.

A baflle 24 is provided above the uppermost tray 8 within the reactor, this baflle serving to direct the incoming reactants or reactivating gases, as the case may be from inlet 8 to the space 2| between the outer edge of the trays and the inner surface of shell I.

In operation, the stream of'heated reactants to be converted or the stream of hot oxygen-containing gases employed to reactivatethe catalyst, as the case may be, enter the upper end of the reactor through nozzle 8 and flood the spaces 2| and I9, from which they flow as a plurality of separate streams of substantially equal volume within the lower-portion o! the groove 26 at the upper end of each of the members II, into which roove the lower end of member II of the next higher tray fits, the packing serving to prevent leakage from spaces I9 into the conduit formed by members II so as to prevent short circuiting of the catalyst beds by the reactants and reactivating gases.

The ring-shaped members I8 in members I I are preferably so adjusted that the effective area through openin s I8 is progressively greater from the uppermost to the lowermost tray so as to obtain a substantially equal volume of flow through each or the catalyst beds- A relatively shallow bed of catalytic material,

indicated at I5 in Fig. 1 is provided'in each of the trays 8 above the member I2.

Openings IS in that portion 'of member II dis posed between screen I2 and deck 9 establish communication between the interior of the tubular member II and the space I] provided between the screen and the deck. In the case here illustrated, In order that each of the trays 8 vmay be identical, a ring-shaped member I8, havmember II of each of the trays nests within the The construction illustrated in Figs. 1 and 2 permits ready removal and replacement of the trays after the upper head 4 of the reactor is removed therefrom. It automatically spaces and aligns the trays and permitsiree longitudinal ex-.

of the invention. One such modification is illustrated in Fig. 3 which will nowbe described.

In Fig. 3 the outer cylindrical shell of the reactor is indicated at 38 and is provided with a flange til at its upper end to which the flanged removable upper head His bolted. The lower head 38 is, in this case, as in Fig. 1, integral with the shell. The upper head 32 is provided with inlet nozzle 34 and the lower head 33 is provided with an outlet nozzle 85.

The catalyst trays 36 of 'Fig. 3 each comprise a relatively flat bottom portion 3'! and upwardly extending inner and outer edges 38 and 39, respectively, which are provided with the respective openings 40 and 4|. The openings in the inner member 38 are backed by a continuous pervious member such as screen 42, which is of such mesh as to retain the catalyst particles of bed 43 in place, and a similar continuous pervious member 44 is provided over the openings H at the outer edge of the tray.

Each tra of the group rests upon the next succeeding lower tray, the bottom portion 31 of each tray serving as a cover "for the next lower tray, and preferably, as here illustrated, a plurality of ring-shaped baiiies 48 depend from the bottom portion 3'! of each tray and extend partway into the catalyst bed 43 of the next lower tray to prevent short circuiting of the vapors and gases across any space 45 which is left beneath the bottom of each tray and the top of the catalyst bed in the next lower tray. a

A vapor tight joint is not required Where the outer portions 39 of the trays meet but, preferably, the lower end of each of the inner edge portions 38 of the trays is constructed to receive suitable packing material 46, against which the upper edge of member 38 of the next lower tray bears to maintain a substantially gas-tight joint ,therebetween. v

An extension 41 of outlet nozzle 35 protrudes upward into the shell of the reactor and terminates in an upper end which is received within the packing recess of the lowermost tray to maintain a tight jointat the point of juncture of this tray with the outlet nozzle.

The uppermost tray is provided wtih a cover 49 provided with baffles 48 and preferably the upper end of the tubular member formed by the walls 38 of the uppermost tray is closed by welding in a disc-shaped member 49 at this point.

With the trays in place in the reactor, their circular inner walls 38 form a continuous central conduit extending from the uppermost through the lowermost tray to portion 41 of outlet nozzle 35, the interior of this conduit being in communication through ports 40 with the catalyst bed on each tray. The trays are sufficiently smaller in external diameter than the internal diameter of shell 30 to provide a substantial space 52 therebetween and a space 5| within the removable upper head 32 of the reactor communicates with space 50 and with the opening through inlet nozzle 34.

Heated hydrocarbon vapors to be converted or hot reactivating gases, as the case may be, pass 5.

permit variation of the effective area of these.

openings from top to bottom of the reactor so Referring to Fig. 4, the hydrocarbon to'be converted, which may comprise, for example, a

stream of hydrocarbon oil to be catalytically through line I08,- line H9 and valve I20 to line cracked, is supplied through line IOI, and valve I02 to heating coil I03 disposed in heater I04 wherein the oil is substantially completely vaporized and heated to approximately the temperature at which it is desired to conduct the catalytic cracking reaction.

The resulting heated hydrocarbon vapors are directed from coil I03 through line I 05 and, while the cracking reaction is taking place in reactor A, they are supplied thereto from line I05 through line I06 and valve I01. While the cracking reaction is taking place in reactor B, the stream of heated hydrocarbons from coil I03 is directed thereto from line I05 through line I06 and valve I01.

Reactors A and B are of the improved form provided by the invention wherein, the catalyst mass in each reactor is divided into a plurality of relatively shallow beds through each of which a substantially equal portion of the stream of heated hydrocarbons supplied to the reactor is passed. Resulting conversion products from each of said relatively shallow beds are discharged from reactor A, while this reactor is employed for conducting the catalytic cracking reaction, through line I08, valve I09 and line III) to suitable separating and recovery equipment of any conventional form, which is not a novel part of the invention and is therefore not illustrated. While reactor B is employed for conducting the catalytic cracking reaction, the conversion products from each of the catalyst beds are discharged from this zone through line I08, valve I09 and line III! to the separating and recovery equipment.

During normal operation of the process, while catalytic cracking is taking place in one of the reactors reactivation of the catalyst is taking place in the other. To accomplish this, a stream of relatively inert gas, such as nitrogen, combustion gases substantially devoid of free oxygen or the like, are directed from anysuitable source through line III and valve H2 and combine in' .containing gases are directed from heater II5 through line H6 and, while reactivation of ,the catalyst is taking place in reactor A, they are directed from line II6 through line 1, valve H8 and line I06 into this zone. While reactivation of the catalyst is taking place in reactor B, the heated oxygen-containing gases from line I I6 are supplied thereto through line I I1, valve I I8 and line I06. 1

The oxygen-containing reactivating gases pass through the reactors in the same manner as the heated hydrocarbon vapors, separate portions of the reactivating gas stream passing through the separate relatively shallow beds of catalytic material in the reactors and burning therefrom the deposited heavy carbonaceous material. sulting spent 0: partially spent reactivating gases and combustion products are dischaged from reactor A, while reactivation is taking place therein,

I2I. While reactivation istaking place in reactor 13, the spent or partially spent reactivating The re gases and combustion products are directed therefrom through line I08, line H9 and valve I20 to line I2I. The gases supplied to line I2I may be discharged from the system, preferably afterheat is recovered therefrom for any desired useful purpose, or they may be, in part, recycled to heatin coil H in any well known manner, not illustrated in the drawings. Preterably, when the spent or partially spent reactivating gases are recycled for further use, deleterious materials such as sulfur compounds, ash and the like are first removed therefrom by any conventional means and their oxygen content and temperature is readjusted to the desired value before they are again introduced into the is only a diagrammatic illustration and, that many modifications of the simple apparatus illustrated may be employed without departing from the scope of the invention. Heater I04, for example, is preferably one of the-several well known conventional forms in which independent control of the temperature of the streams discharged from coils I03 and H5 is obtained or, when desired, separate heaters may be employed for heating the reactants and the reactivating gases. The invention also contemplates the use of more than two reactors. in which case two or more reactors may be connected for either parallel or series flow of the reactants and reactivating gases therethrough. Special stream diverting or switching valves which handle more than a single stream may also be employed within the scope of the invention to replace the switching valves here illustrated in a conventional manner.

The invention also definitely contemplates purging the reactor in which catalytic cracking has been taking place of hydrocarbon vapors and gases prior to each reactivating period and purging the reactor in which reactivation has been taking place of oxygen-containing gases prior to each cracking period. This is accomplished by discontinuing the supply of oxygen to'the system for a short period immediately preceding and immediately following each alternation of the reactors to allow the relatively inert gases to sweep the hydrocarbon vapors and gases from the reactor in which reactivation is about to be initiated and to sweep the oxygen-containing gases from the reactor in which cracking is about to be initiated.

When starting the operation, the reactors are preferably preheated and otherwise preconditio ed by circulating hot relatively inert gases ro actor A is to be first used for conducting the catalytic cracking operation, inert gases supplied to .0011 H5 through line III and valve H2, and

heated therein to a temperature somewhat above that at which it is desired to conduct the cracking reaction, are supplied through line H6, line coil I I5 therethrough. For example, if re- I I1, valve I I0 and line I00 to reactor A and therefrom through line I08, line H9 and valve I20 to line III for a suflicient length of time to substantially purge the reactor of air and heat it to the desired temperature. Following such preconditioning of reactor A, the hot inert gases are diverted to reactor B to likewise precondition the same while the heated hydrocarbons. from coil I03 are supplied to reactor A and the first cracking step of the operation is conducted in the latter. Following the first cracking step in reactor A and preconditioning of reactor B, the heated hydrocarbons are supplied to reactor B wherein the cracking reaction is continued and the heated inert gases are supplied to reactor A for a sufllcient length of time to substantially purge this reactor of hydrocarbon vapors and gases, then air is admitted to the stream of inert gases and reactivation of the catalyst in reactor A is accomplished while the cracking reaction continues in reactor B. Shortly before the cracking step in reactor B is completed, the supply or oxygen to the system is discontinued to purge reactor A of oxygen-containing gases and then the stream of heated hydrocarbons is diverted to this reactor while the stream of hot inert gases is diverted to reactor B to purge it of hydrocarbon vapors and gases, oxygen is then again admitted to the system to reactivate the catalyst in reactor B and from this point on the reactors are periodically alternated with purging in each reactor preceding each cracking step and"each reactivating step therein.

As an example of one specific operation ofthe process, as applied to the catalytic cracking of hydrocarbon oil, the charging stock is a Mid- Continent parafilnic distillateof approximately 29 A. P. I. gravity having an initial boiling point of approximately 330 F. One volume of charging stock is combined with approximately 4.5 volumes of primary reflux condensate from the fractionator of the system. This primary reflux condensate .has an initial boiling point of about 490 F. and a 50% boiling point of approximately 640 F. The mixture is substantially vaporized and heated prior to its introduction into the reactor, to which it issupplied at a temperature of about 935 F. The'average temperature in the reactor is approximately 912- F. and the combined feed (charging oiland primary reflux condensate) is supplied to the reactor at the rate of approximately 4 cubic feet per hour per cubic footoi space occupied by the catalyst. A superatmospheric pressure of approximately30 pounds per square inch is employed at the inlet of the reactor and the outlet pressure is approximately 28 pounds per square inch, superatmospheric.

vDuring reactivation, combustion gases containing approximately 2.5% by volume of oxygen are supplied to the reactor at a temperature of approximately 1000 F. and a superatmospheric pressure of approximately '75 pounds per square inch. The average of the peak temperatures encountered during the reactivating steps is approximately 1295 F. and the pressure at the outlet of the reactor during reactivation is approx-- imately 65 pounds per square inch.

In an operation such as above described there may be obtained per barrel of charging oil em- I ployed, approximately 64.5% of 400 F. end-point square inch. The octane number of this product, as determined by the motor method, may

be approximately 78.5. In addition, approximately 13.5% of secondary reflux condensate having a gravity of approximately 27 A. P. I. and an end-boiling point of approximately 615 F. may be produced. The residual liquid product of the process may amount to approximately 3.5% by volume of the charging stock and have a gravity of approximately 17 A. P. I. and a Saybolt universal viscosity of approximately 75 seconds at 122 F. The gaseous products of the process (exclusive of combustion gases and air) may contain approximately 22% of hydrogen and more than 11% of readily polymerizable oleflns which will yield an additional to 6%, based'on the charging oil, of good antiknock polymer gasoline by catalytic polymerization.

1. A reaction vessel of the class described comprising, in combination, a vertically elongated outer shell, a plurality of trays each adapted to retain therein a bed of granular. contact material and disposed within said shell in superimposed spaced apart relation, the trays being spaced from said shell thereby forming a longitudinally continuous fluid passageway between the tray assembly and the shell, a perforate false bottom in each tray above which said bed of granular contact material is disposed, an imperforate bottom wall on each tray spaced from the false bottom to provide a space therebetween beneath said bed, each of said trays having a centrally disposed tube which is an integral part of the tray structure, said tubes forming a single vertically disposed central fluid conduit when the trays are superimposed one above the other and being detachably joined at their ends to vertically space and align the trays, said central conduit being provided with vertically spaced openings through its wall at the elevation of said spaces in the trays between the bottom wall and the false bottom to establish communication between the latter spaces and the interior of the central conduit, a fluid inlet adjacent one end of the shell communicating with said longitudinally continuous passageway, and a fluid outlet adjacent the opposite end of the shell communicating with said central fluid conduit.

2. A reaction vessel such as defined in claim 1, wherein the tray assembly is supported by said central conduit and the weight of the tray assembly is transmitted by said central conduit to the shell of the reactor.

3. A catalytic reaction vessel comprising in series a combination of trays, each of said trays comprising a substantially cylindrical 'outer wall, a concentric substantially cylindrical central member of lesser diameter and extending above and below the said outer wall, an imperforate bottom plate joining the outer wall from its bottom to the cylindrical inner member in such manner that a projecting tongue is formed by the lower end of said inner member, a perforated plate disposed'above 'said bottom plate, said central member having openings provided through its wall at points between the bottom plate and the perforated plate, said central cylindrical member being provided with engaging means disposed in the upper end thereof, said trays being disposed in a cylindrical shell withclosed ends so that the torm'ue at the lower end of the central cylindrical memberof' each tray. engages with the engaging means disposed" in the upper end of. the cylid-z drical central member of the tray below it, said shell being of larger diameter than the trays so that an annular space is formed between the outer walls of the trays and the shell inlet means for admitting fluids in the upper end Of the shell, outlet means for the reaction products in the lower end of the shell, and conduitmeans integrally attached to the reactor shell in registration-with the outlet means and havingengaging means disposed in its upper end with which the projection tongue of the lowermost tray in the shell engages.

4. A catalyticreaction vessel comprising, in

' combination, a series of trays, each of said trays comprising a substantially cylindrical outer wall, a central member of lesser diameter and longer than said outer wall, an imperforate bottom plate joining the outer wall from its bottom to the cylindrical inner member in such manner that a projection is formed by the lower end of said inner member, a perforate member disposed above said bottom plate, said central mem berv having openings provided through its wall at points between the bottom plate and the perforate member, said central cylindrical member being provided with a tongue at one end thereof and complementary engaging means at its opposite end, said trays being disposed in superimposed relation within a cylindrical shell having closed ends so that the tongue at the one end of the central cylindrical member of .each tray engages with the complementary engaging means disposed at the adjoining end of the cylindrical central member of the succeeding tray, said shell being of larger diameter than the trays so that an annular space is formed between the outer walls of the trays and the shell, inlet means for admitting fluids in one end of the shell, outlet means for the reaction products at the opposite end of the shell, and a conduit secured to' the reactor shell in registration with the outlet means and having engaging means disposed in its upper end with. which the projecting portion of the lowermost tray in the shell engages.

,5. A tray for retaining a bed of granular contact material in a reactor, comprising an openended cylindrical central member, a cylindrical outer wall spaced from and extending about said central member to provide an annular space therebetween, means forming an annular groove at the'upper end of said central member, the

opposite end of the central member extendin below the lower end of said outer wall, a horizontal annular closure plate joining the lower end of said outer wall with the central member at a point above the bottom of the latter, and a horizontalperforate annular retaining member between said outer wall and said central member disposed above and spaced from said closure plate, said central member. being apertured in the portion thereof between said retaining member and said closure plate.

6. A reactor comprising-a cylindrical shell; a plurality of superimposed annular trays within and spaced from the shell; each of said trays comprising an outer cylindrical wall, a centralv open-ended tubular member within and spaced from said outer wall and protruding below the lower end of the outer wall, a horizontal annular closure plate joining the lower end of the outer wall with said tubular member at a point above the bottom of the latter, and a horizontal perforate annular retaining member between the outer wall and the tubular member and disposed above and spacedfrom said closure plate;

concentric substantially cylindricalv means forming an annular groove at the upper end or each of said tubular members; the lower protruding end of the tubular member of an upper one of said trays being disposed in the annular groove of the tubular member of the next lower tray, thereby forming a vertical central conduit within said shell; apertures in.

conduit.

said central conduit in the portion of each of 5 PERCY MATHER. 

